Olefin conversion process

ABSTRACT

A process for the production of C 4  olefins, which may include: contacting a hydrocarbon mixture comprising alpha-pentenes with an isomerization catalyst to form an isomerization product comprising beta-pentenes; contacting ethylene and the beta-pentenes with a first metathesis catalyst to form a first metathesis product comprising butenes and propylene, as well as any unreacted ethylene and C 5  olefins; and fractionating the first metathesis product to for an ethylene fraction, a propylene fraction, a butene fraction, and a C 5  fraction.

CROSS-REFERENCE TO RELATED APPLICATION

This application, pursuant to 35 U.S.C. §120, claims benefit to U.S.patent application Ser. No. 14/548,500 filed Nov. 20, 2014, now U.S.Pat. No. ______, which pursuant to 35 U.S.C. §119(e), claims priority toU.S. Provisional Application Ser. No. 61/906,637, filed Nov. 20, 2013.Each of these applications is incorporated herein by reference in theirentirety.

BACKGROUND OF DISCLOSURE

1. Field of the Disclosure

Embodiments disclosed herein relate generally to the processing of a C₅olefin stream, such as may be formed from a C₅ hydrocarbon cut from acracking process, for conversion of the C₅ olefins to butenes viaisomerization and metathesis.

2. Background

It is known to convert pentenes to propylene via metathesis. Forexample, when linear pentenes are fed to a conventional metathesisreactor, having a catalyst bed including a mixture of isomerization andmetathesis catalysts, the following reactions may occur:

1-pentene→2-pentene (Isomerization);  (a)

2-pentene+ethylene→1-butene+propylene (Metathesis);  (b)

1-butene→2-butene (Isomerization);  (c)

2-butene+ethylene→2 propylene (Metathesis).  (d)

1-Pentene is isomerized to 2-pentene. The metathesis reaction of1-pentene with ethylene is non-productive (products are same asreactants). The overall linear C₅ olefin reaction for the production ofpropylene can thus be shown as:

1 mol linear pentene+2 mol ethylene→3 mol propylene.

Butadiene demand, however, is increasing. Butadiene is a versatile rawmaterial used in the production of a wide variety of synthetic rubbers,polymer resins and chemical intermediates. The largest uses forbutadiene are the production of styrene butadiene rubber andpolybutadiene rubber, which are used mainly in tire products. Butadieneis also one of the components used in the manufacture ofacrylonitrile-butadiene-styrene, styrene-butadiene copolymer latex,styrene-butadiene block copolymers and nitrile rubbers. There is agrowing demand for butadiene caused by the growth in tire demand as wellas reduced natural rubber production.

The major source of butadiene is as a byproduct in the steam cracking ofnaphtha and gas oil to make ethylene and propylene. Steam cracking is aprocess by which hydrocarbon molecules are exposed to very hot steam,causing them to break apart into smaller molecules. Separation ofbutadiene from the other products of the steam cracking processtypically includes the use of extractive distillation. Other potentialsources for the production of butadiene include converting feed stockscomprising butene and butane compounds and mixtures thereof tobutadiene.

SUMMARY OF THE DISCLOSURE

Embodiments disclosed herein relate generally to the production ofbutenes from a C₅ feedstock. The processes disclosed herein provide forconverting a low-valued stream, C₅'s, for which demand is decreasing,such as due to regulatory changes decreasing RVP requirements and thuslimiting C₅ blending in fuels, to a higher valued product, includingbutenes or butenes and propylene.

In one aspect, embodiments disclosed herein relate to a process for theproduction of C₄ olefins, the process comprising: contacting ahydrocarbon mixture comprising alpha-pentenes with an isomerizationcatalyst to form an isomerization product comprising beta-pentenes;contacting ethylene and the beta-pentenes with a first metathesiscatalyst to form a first metathesis product comprising butenes andpropylene, as well as any unreacted ethylene and C₅ olefins; andfractionating the first metathesis product to for an ethylene fraction,a propylene fraction, a butene fraction, and a C₅ fraction.

In another aspect, embodiments disclosed herein relate to a process forthe production of C₄ olefins. The process may include: feeding ethyleneand a C₅ olefin stream comprising a mixture of C₅ olefins including atleast one of 1-pentenes, 2-methyl-1-butene, and 3-methyl-1-butene to anisomerization/metathesis reactor including a first reaction zonecomprising an isomerization catalyst and a second reaction zonecomprising a first metathesis catalyst; contacting the C₅-olefin streamwith the isomerization catalyst in the first reaction zone to form anisomerization product comprising internal-pentenes including at leastone of 2-pentenes and 2-methyl 2-butene; contacting the internalpentenes with ethylene in the presence of the metathesis catalyst in thesecond reaction zone to form a first metathesis product comprisingpropylene and butenes, including at least one of 1-butene and isobutene,as well as any unreacted ethylene and unreacted C₅ olefins; feeding thefirst metathesis product to a fractionation system; fractionating thefirst metathesis product in the fractionation system to form an ethylenefraction, a propylene fraction, a butene fraction, and a pentenefraction; feeding the propylene fraction to a metathesis reactor andcontacting the propylene with a second metathesis catalyst, which may bethe same or different than the first metathesis catalyst, to convert atleast a portion of the propylene to ethylene and 2-butene and recover asecond metathesis product; and feeding the second metathesis product tothe fractionation system.

In another aspect, embodiments disclosed herein relate to a system forthe production of C₄ olefins. The system may include: a flow conduit forfeeding ethylene and a C₅-olefin stream comprising a mixture of C₅olefins including at least one of 1-pentenes, 2-methyl-1-butene, and3-methyl-1-butene to an isomerization/metathesis reactor including afirst reaction zone comprising an isomerization catalyst and a secondreaction zone comprising a first metathesis catalyst; theisomerization/metathesis reactor for contacting the C₅-olefin streamwith the isomerization catalyst in the first reaction zone to form anisomerization product comprising internal-pentenes including at leastone of 2-pentenes and 2-methyl-2-butene, and for contacting the internalpentenes with the metathesis catalyst in the second reaction zone toform a first metathesis product comprising propylene and butenes,including at least one of 1-butene and isobutene, as well as anyunreacted ethylene and unreacted C₅ olefins; a fractionation system forfractionating the first metathesis product in the fractionation systemto form an ethylene fraction, a propylene fraction, a butene fraction,and a pentene fraction; a metathesis reactor for contacting thepropylene fraction with a second metathesis catalyst, which may be thesame or different than the first metathesis catalyst, to convert atleast a portion of the propylene to ethylene and 2-butene and recover asecond metathesis product; and a flow conduit for feeding the secondmetathesis product to the fractionation system.

Other aspects and advantages will be apparent from the followingdescription and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a simplified process flow diagram of a process for producingbutenes according to embodiments disclosed herein.

FIG. 2 is a simplified process flow diagram of a process for producingbutenes according to embodiments disclosed herein.

FIG. 3 is a simplified process flow diagram of anisomerization/metathesis reactor for use in processes for producingbutenes according to embodiments disclosed herein.

DETAILED DESCRIPTION

In one aspect, embodiments herein relate to the processing of C₅hydrocarbons to form lighter olefins, such as butenes. In anotheraspect, embodiments disclosed herein relate to the conversion of C₅olefins to butene via an integrated isomerization and metathesisprocess, and to production of butadienes via cracking of the buteneproducts. Embodiments disclosed herein provide systems and processes forthe production of C₄ olefins.

Feedstocks useful in embodiments herein include various C₅-containinghydrocarbon streams, especially those containing alpha-pentenes,including 1-pentene, 2-methyl 1-butene, and 3-methyl 1-butene. Mixedpentene feedstocks useful in embodiments disclosed herein may includelinear pentenes and isopentenes. Mixed pentene feedstocks may alsoinclude various other hydrocarbon components, including C₄ to C₆paraffins and olefins. In some embodiments, the mixed pentene feedstockmay be a C₅ hydrocarbon fraction from a catalytic or steam cracker,where the C₅ fraction may include linear pentenes, isopentene,n-pentanes, and isopentanes. In some embodiments, the mixed pentenefeedstock may include isopentene at a concentration of greater than 40mol %, 50 mol %, or 60 mol %.

The alpha-pentenes in the hydrocarbon stream may be contacted with anisomerization or hydroisomerization catalyst to form an isomerizationproduct comprising internal-pentenes, such as converting 1-pentenes to2-pentenes, and 2-methyl 1-butene and 3-methyl 1-butene to 2-methyl2-butene. Ethylene and the internal-pentenes may then be contacted witha first metathesis catalyst to form a first metathesis productcomprising butenes, including 1-butene and isobutene, and propylene, aswell as any unreacted ethylene and C₅₊ olefins. The first metathesisproduct may then be fractionated to form an ethylene fraction, apropylene fraction, a butene fraction, and a C₅₊ fraction.

The propylene fraction, or a portion thereof, may be recovered as aproduct stream. Alternatively or additionally, production of butenes inthe process may be increased via contacting of the propylene with asecond metathesis catalyst, which may be the same or different than thefirst metathesis catalyst, to convert at least a portion of thepropylene to ethylene and 2-butene and form a second metathesis product.The first metathesis product and the second metathesis product may befractionated in a common fractionation system in some embodiments.Providing an additional propylene metathesis stage provides flexibilityin the product mixture, allowing one to adjust the rate of withdrawingthe propylene product stream to produce a selected ratio of butene topropylene product.

The ethylene fraction and the C₅₊ fraction may also be recycled to theisomerization stage or the pentene metathesis stage to increase theoverall conversion of the ethylene and pentenes in the system.

Prior to isomerization and metathesis, some pre-processing of the C₅olefin-containing stream may be desired. For example, it is generallydesirable to limit the content of cyclopentene and/or dienes in thehydrocarbon stream fed to isomerization. In some embodiments, theprocess may include fractionating a C₅ olefin-containing hydrocarbonstream to form the C₅ feed to the isomerization stage. Depending uponthe tolerance of the catalyst to cyclopentene, it may be desirable tolimit the amount of cyclopentene in the feed. In some embodiments, thehydrocarbon mixture recovered from the fractionation contains less than0.5 wt % cyclopentene; less than 0.4 wt %, less than 0.3 wt %, and lessthan 0.25 wt % in other embodiments. It may also be desired toselectively hydrogenating dienes in the hydrocarbon stream prior to,subsequent to, or concurrent with the above-noted fractionation stage toremove cyclopentenes. For example, catalytic distillation may be used toconcurrently selectively hydrogenate dienes and separate cyclopentenesfrom the C5 feedstock.

Following recovery, the butene fraction may be further processed, ifdesired, to form butadiene or other end products. For example, butadienemay be produced by dehydrogenation of the butene fraction. Isobutene mayalso be separated from normal butenes in the butene fraction via atleast one of isomerization and fractionation. The isobutene may thenundergo skeletal isomerization to form additional normal butenes;alternatively, the isobutene may be etherified to produce MTBE, ETBE orother end products.

Referring now to FIG. 1, a simplified process flow diagram of a processfor the production of C₄ olefins according to embodiments herein isillustrated. A C₅-olefin containing stream 2, which may include one ormore C₅ olefins such as at least one of 1-pentenes, 2-methyl 1-butene,and 3-methyl 1-butene, may be fed to an isomerization/metathesisreaction system 5. The isomerization/metathesis reaction system 5 mayinclude a first reaction zone 6, including one or more reactors inparallel or series, each containing an isomerization catalyst. Theisomerization/metathesis reaction system 5 may also include a secondreaction zone 10, including one or more reactors in parallel or series,each containing a metathesis catalyst.

In other embodiments, such as illustrated in FIG. 3, where like numeralsrepresent like parts, the isomerization/metathesis reaction system 5includes one or more reactors in parallel, each including a first(upstream) isomerization reaction zone 6 and a second (downstream)metathesis reaction zone 10. When contained in the same reactor, it ispreferred that the isomerization catalyst beds 6 be segregated from themetathesis reaction beds 10 such that isomerization and metathesis ofthe desired butene reaction products does not occur, such as would occurwhere the isomerization and metathesis catalysts are mixed together, asis common in other isomerization and metathesis processes for producingpropylene from C₅ olefins. In some embodiments, theisomerization/metathesis reactor 5 is a downflow reactor, theisomerization reaction zone 6 including one or more beds ofisomerization catalyst in an upper portion of the reactor and themetathesis reaction zone 10 including one or more beds of metathesiscatalyst in a lower portion of the reactor.

In the first reaction zone 6, the C₅ olefins and the ethylene arecontacted with the isomerization catalyst, and reacted at suitablereaction conditions, to form an isomerization product stream 8 includinginternal-pentenes, such as 2-pentenes and 2-methyl 2-butene.Isomerization reaction conditions may include temperatures in the rangefrom 20° C. to about 600° C., such as about 200° C. to about 400° C.,and pressures in the range from about 14 psig to about 2000 psig, suchas about 200 psig to about 600 psig. The first reaction zone 6 may beconfigured and operated such that an equilibrium mixture rich ininternal pentenes is achieved. For example, an equilibrium mixture atoperating conditions of about 300° C. and 400 psig may have a high ratioof internal olefins relative to alpha olefins, such as a 2-pentene to1-pentene ratio of about 6 (about 5 to about 7) and a 2-methyle-2-buteneto 3-methyl-1-butene plus 2-methyl-1-butene ratio of about 2 (about 1.5to about 2.5) for feed to the downstream metathesis reaction zone.

The internal pentenes in isomerization product stream 8 may then becontacted with the metathesis catalyst in the second reaction zone 10 atsuitable reaction conditions to form a first metathesis product 12.First metathesis product 12 may include propylene and butenes, includingat least one of 1-butene and isobutene, as well as any unreactedethylene and unreacted C₅ olefins.

Ethylene stream 4 may be fed to reaction system 5 at any point upstreamof metathesis reaction zone 10. For example, ethylene may be co-fed withthe C₅ olefin stream 2 to isomerization reaction zone 6. When fed toisomerization reaction zone 6, the ethylene is essentially unaffected bythe isomerization catalyst. In other embodiments, the ethylene may befed intermediate reaction zone 6 and reaction zone 10. For reactorsincluding multiple beds of metathesis catalyst, additional ethylene maybe fed intermediate the multiple beds, if desired.

The metathesis product 12 may then be fed to a fractionation system 14for separation and recovery of the various products and any unreactedfeed components. In some embodiments, such as illustrated, themetathesis product 12 may be fractionated in the fractionation system 14to form an ethylene fraction 16, a propylene fraction 18, a butenefraction 28, and a pentene (C₅ or C₅₊) fraction 30. Ethylene fraction 16and/or pentene fraction 30 may be recycled to reaction zone 5. A C₅₊purge 32 may also be withdrawn to limit the buildup of various heavy orunwanted compounds within the system.

The propylene fraction 18 may be fed to a metathesis reaction zone 24,which may include one or more reactors or reaction zones operating inseries or parallel, each containing a metathesis catalyst, which may bethe same or different than the metathesis catalyst in reaction zone 10.The propylene may then be contacting with the metathesis catalyst atappropriate reaction conditions to convert at least a portion of thepropylene to ethylene and 2-butene. A propylene auto-metathesis product26 may then be recovered from reactor 24 and fractionated to recover theethylene, 2-butene, and any unreacted propylene. In some embodiments,metathesis product 26 may be fed to fractionation system 14 forseparation along with metathesis product 12 to recover the desiredproducts and recycle streams. As noted above, a propylene product stream20 may be withdrawn, as desired.

Referring now to FIG. 2, a simplified process flow diagram of a processfor the production of C₄ olefins according to embodiments herein isillustrated, where like numerals represent like parts. In thisembodiment, a mixed C₅ feed stream 34 is pre-processed to form C₅ olefinfeed stream 2. As illustrated, the mixed C₅ stream 34, which may includedienes (linear, pentadienes; branched, isoprene, and cyclic,cyclopentadiene) may be fed to a catalytic distillation reactor system36 for concurrent reaction and separation of the dienes and other heavyC₅ components in the feed (such as pentanes, if present). The dienes maybe converted via hydrogenation into their corresponding olefins inreaction zone 38. Additionally, cyclopentadiene may be converted viadimerization to form dicyclopentadiene, which may be recovered alongwith the other heavy components in bottoms stream 40. Fractionation andhydrogenation conditions in catalytic distillation reactor system 36 maybe selected to limit the diene content in the overheads 2, as well as tolimit the amount of cyclopentene in the overheads 2, if necessary.

The process of FIG. 2 also illustrates one possibility for downstreamprocessing of butene product stream 28. As illustrated, butene productstream 28, which includes 1-butene and isobutene, may be fed to acatalytic distillation reactor system 42, which may include one or morereaction zones 44 containing an isomerization catalyst. In catalyticdistillation reactor system 42, the 1-butene may be isomerized to form2-butene to facilitate the concurrent separation of isobutene in thebutene fraction 28 from the normal butenes. The separated products,isobutene 46 and 2-butene 48, may then be used separately in downstreamprocesses, as desired.

The above-described C₅-to-C₄ olefin conversion process (V2IV-OCT™)allows for the production of C₄ olefins (isobutene+n-butenes) from anyraw industrial streams that contain pentenes (linear, branched, andcyclic). Such streams are readily available from various industrialprocess streams that contain C₅ olefins, such as those found in: crudefractions, MTO (Methanol to Olefins) by-product streams; steam crackerpyrolysis gasoline streams; and FCC (Fluid Catalytic Cracking) recoverystreams. Only a small amount of additional ethylene is required for theproduction of butenes from the C₅ olefins.

The first step in some embodiments of the process is to attain a C₅ feedessentially free of C₅ dienes (such as less than 1000 ppm). This may beachieved via selective hydrogenation of various C₅ dienes and fraction.The selective hydrogenation provides for increasing the potential usefulC₅ olefins such as linear pentenes from linear pentadienes. The raw C₅smay also be fractionated and hydrogenated simultaneously via reactivedistillation processes. Butenes may then be produced from pentenes viathe utilization of isomerization and metathesis. In some embodiments,the metathesis catalysts may be tungsten oxide on silica, and thedouble-bond isomerization catalyst may be magnesium oxide. The overallprocess, with propylene metathesis, requires two separate reactors, aS-OCU (segregated olefin conversion unit) reactor and a metathesis-onlyreactor, and a simple separation train that includes a deethylenizer, adepropylenizer, and a debutenizer.

Processes according to embodiments herein provide for the conversion ofboth linear and branched C₅ olefins into linear butanes and isobutene,respectively. The isobutene in the C₄ product stream can be furtherseparated via a isomerization and distillation (concurrently, in acatalytic distillation deisobutenizer (CD-DeIB™), or serially). Theisobutene may then be processed further, such as via skeletalisomerization, to generate additional n-butenes if desired.

Processes disclosed herein may allow a producer increased flexibilityfor managing their olefins portfolio and the ability to adapt to dynamicmarket conditions. Processes herein provide a completely new method forproducing butenes, recently growing in demand, using low-value C₅olefins as feedstock.

As shown in FIG. 2, the overhead process stream 2 from the catalyticdistillation reactor 36, is sent to the reaction zone 5. Stream 2, whichprimarily consists of linear pentenes and branched C₅ olefins and isessentially free of C₅ dienes with limited amounts of cyclopentene, isused to produce both linear and branched butenes via the overallC₅-to-C₄ process. These streams may contain some C₅ and C₄ alkanes thatare essentially inert in all subsequent reactors (reactors 1 and 2) butneed to be purged from various locations to avoid building up in theprocess loops.

In the upstream double-bond isomerization section 6, double-bondisomerization of the n-pentenes and branched pentenes are the onlyreactions (reaction 1, reaction 2, and reaction 3) that occur andprovides an equilibrium mixture of pentenes rich in internal double bondpentenes (beta-pentenes, such as 2-pentene and 2-methyl-2-butene) at thestarting point of the downstream metathesis catalyst reaction zone 10.

1-pentene←→2-pentene  (Reaction 1)

3-methyl-1-butene←→2-methyl-2-butene  (Reaction 2)

2-methyl-1-butene←→2-methyl-2-butene  (Reaction 3)

In the downstream metathesis section 10, as the cross-metathesisreactions with ethylene are non-productive for any alpha-olefin, such as1-pentene, 2-methyl-1-butene, and 3-methyl-1-butene, only the followingnet reactions occur in the metathesis section 10 that produce propyleneand butenes (isobutene and 1-butene).

2-pentene+ethylene←→1-butene+propylene  (Reaction 4)

2-methyl-2-butene+ethylene←→isobutene+propylene  (Reaction 5)

The metathesis reactor effluent is then fed to the primary separationtrain, which may include a deethylenizer, depropylenizer, anddebutenizer. The product butenes are separated from the debutenizeroverhead stream and may be sent to a CD-DeiB that allows for the productto be separated into isobutene and linear n-butenes. The linearn-butenes stream can be used for producing butadiene or other products.The isobutene stream can be sent to a MTBE unit for production of MTBEor sent to a skeletal isomerization unit for conversion into additionallinear butenes if desired.

The separated propylene from the depropylenizer overhead stream may besent to a metathesis-only reactor (reactor 24) to form additional2-butene products and ethylene recycle. This reaction can be written as:

Propylene←→2-butene+ethylene  (Reaction 6)

The product stream containing 2-butene, ethylene and unreacted propyleneis added back to the beginning of the separation train for separationand recycle of ethylene and propylene. Ethylene formed from reaction 6is separated via the deethylenizer and recycled back to the reactionzone 5, thus lowering the requirements for fresh ethylene feed 4, whichmay be limited for some producers.

Depending on the cyclopentene in the overhead stream 2 from unit 36entering the reaction zone 5, purge 32 may be taken from the C₅ recyclestream 30 to prevent cyclopentene and other C₅₊ heavies buildup in theloop.

The depropylenizer overhead stream can be split to produce polymer-gradepropylene, for cases where the client may need some propylene on-demand,and feed to the metathesis only reactor zone 24 to produce butenes. Therelative production rates for butenes and propylene product can beessentially controlled by how much is withdrawn via stream 20.Therefore, the V2IV-OCT process provides additional flexibility formanaging olefins production between propylene and butenes, usingpentenes as feed stock.

Embodiments disclosed herein also relate to a system for the productionof C₄ olefins. The system may include a flow conduit for feedingethylene and a C₅ olefin stream comprising a mixture of C₅ olefinsincluding at least one of 1-pentenes, 2-methyl-1-butene, and3-methyl-1-butene to an isomerization/metathesis reactor including afirst reaction zone comprising an isomerization catalyst and a secondreaction zone comprising a first metathesis catalyst. The system alsoincludes the isomerization/metathesis reactor for contacting the C₅olefin stream with the isomerization catalyst in the first reaction zoneto form an isomerization product comprising internal-pentenes includingat least one of 2-pentenes and 2-methyl 2-butene, and for contacting theinternal pentenes with the metathesis catalyst in the second reactionzone to form a first metathesis product comprising propylene andbutenes, including at least one of 1-butene and isobutene, as well asany unreacted ethylene and unreacted C₅ olefins. A fractionation systemmay then be used for fractionating the first metathesis product in thefractionation system to form an ethylene fraction, a propylene fraction,a butene fraction, and a pentene fraction.

In some embodiments, the system may also include a metathesis reactorfor contacting the propylene fraction with a second metathesis catalyst,which may be the same or different than the first metathesis catalyst,to convert at least a portion of the propylene to ethylene and 1-buteneand recover a second metathesis product. A flow conduit may also beprovided for feeding the second metathesis product to the fractionationsystem.

In embodiments disclosed herein, the isomerization/metathesis reactor 5,6, 10, and/or the metathesis reactor 24 may be operated at a pressurebetween 2 and 40 atmospheres, and between 5 and 15 atmospheres in otherembodiments. The reactors may be operated such that the reactiontemperature is within the range from about 30° C. to about 600° C.;within the range from about 200° C. to about 450° C. in otherembodiments; and from about 250° C. to about 400° C. in yet otherembodiments. The isomerization and metathesis reactions may be performedat a weight hourly space velocity (WHSV) in the range from about 2 toabout 200 in some embodiments, and from about 6 to about 40 in otherembodiments.

The reactions may be carried out by contacting the olefin(s) with theisomerization and/or metathesis catalysts in the liquid phase or the gasphase, depending on structure and molecular weight of the olefin(s). Ifthe reaction is carried out in the liquid phase, solvents or diluentsfor the reaction can be used. Aliphatic saturated hydrocarbons, e.g.,pentanes, hexanes, cyclohexanes, dodecanes and aromatic hydrocarbonssuch as benzene and toluene are suitable. If the reaction is carried outin the gaseous phase, diluents such as saturated aliphatic hydrocarbons,for example, methane, ethane, and/or substantially inert gases, such asnitrogen and argon, may be present. For high product yield, thereactions may be conducted in the absence of significant amounts ofdeactivating materials such as water and oxygen.

The contact time needed to obtain a desirable yield of reaction productsdepends upon several factors such as the activity of the catalyst,temperature, pressure, and the structure of the olefin(s) to beisomerized and/or metathesized. Length of time during which theolefin(s) are contacted with catalyst can vary between 0.1 seconds and 4hours, preferably from about 0.5 sec to about 0.5 hrs. The isomerizationand metathesis reactions may be conducted batch-wise or continuouslywith fixed catalyst beds, slurried catalyst, fluidized beds, or by usingany other conventional contacting techniques.

The catalyst contained within the metathesis reactor may be any knownmetathesis catalyst, including oxides of Group VIA and Group VIIA metalson supports. Catalyst supports can be of any type and could includealumina, silica, mixtures thereof, zirconia, magnesia, titania, andzeolites. In some embodiments, the metathesis catalyst is tungsten oxideon silica.

The double bond isomerization catalyst may be any known double bondisomerization catalyst. In some embodiments, the double bondisomerization catalyst may be one of magnesium oxide, calcium oxide,aluminum oxide, or mixed Mg—Al oxides (e.g, hydrotalcite-derived mixedoxides), among other possible catalysts.

In some embodiments, the double bond isomerization catalyst may be analumina-titania catalyst. The catalyst may be a γ-alumina-titaniacrystalline mixture including active sites that catalyze the positionalisomerization of olefins, and may be in the form of pellets, extrudates,and the like, and will typically have an effective diameter of 0.5 mm to5 mm, such as in the range from 1 mm to 4 mm, or in the range from 2 mmto 3 mm. In some embodiments, the alumina-titania catalyst may have acomposition of titanium with a lower limit of 0.01, 1, 2, 3, 4, 5, 10,15, 20, or 25 to an upper limit of 15, 20, 25, 30, 35, 40, 45, or 50 wt%, where any lower limit may be combined with any upper limit.γ-Alumina-titania catalyst herein may have a surface area in someembodiments greater than 200 m²/g, in other embodiments greater than 250m²/g, in other embodiments greater than 300 m²/g, in other embodimentsgreater than 350 m²/g, and in other embodiments greater than 400 m²/g.The γ-alumina-titania catalysts may be tolerant of oxygenated speciesthat are typically considered a poison, such as to MgO type catalysts,may act as an oxygenate scavenger protecting downstream catalyst beds,and in some embodiments may have activity for dehydration of alcohols inaddition to isomerization activity. The γ-alumina-titania catalysts mayalso be more forgiving with respect to cyclopentene purity of the feed,and may allow greater than 5 wt %, greater than 7.5 wt %, or evengreater than 10 wt % cyclopentene to be present in the feed, potentiallynegating typical upstream processes required to remove cyclopentene fromthe feed. These γ-alumina-titania catalysts may be used alone, such asin an isomerization only reactor or in an isomerization catalyst bed ina segregated OCU, or may be used in admixture with other isomerizationcatalysts or metathesis catalysts.

The effluent from the metathesis reactor may be sent to a separationsystem to separate the metathesis effluent into carbon number groups bytechnology well known in the art. For example, the products of theseparation system may include an ethylene stream, a propylene stream, aC₄ stream, and a C₅₊ stream. The propylene stream may be recovered as aproduct stream, which may also undergo further purification steps toobtain a high purity propylene product. The C₅ stream may be recycledback to the metathesis reactor or a pre-treatment stage, such asisomerization or fractionation. The ethylene stream may be recovered asa product stream or may be recycled back to the metathesis reactor foruse as an ethylene feedstock for the conventional metathesis reaction.

As described above, embodiments disclosed herein provide an efficientprocess for converting mixed pentenes to butenes. Advantageously,embodiments herein may provide for conversion of a low-value feedstock,C₅s, to a higher valued end product, including butenes and optionallypropylene. The conversion may be accomplished with little or no overallnet consumption of ethylene. Processes disclosed herein also provideadditional flexibility for managing olefins production between propyleneand butenes using pentenes as a feedstock.

While the disclosure includes a limited number of embodiments, thoseskilled in the art, having benefit of this disclosure, will appreciatethat other embodiments may be devised which do not depart from the scopeof the present disclosure. Accordingly, the scope should be limited onlyby the attached claims.

What is claimed:
 1. A system for the production of C₄ olefins, thesystem comprising: an isomerization reaction zone for contacting ahydrocarbon mixture comprising alpha-pentenes with an isomerizationcatalyst to form an isomerization product comprising beta-pentenes; afirst metathesis reaction zone for contacting ethylene and thebeta-pentenes with a first metathesis catalyst to form a firstmetathesis product comprising butenes and propylene, as well as anyunreacted ethylene and C₅ olefins; a separation system for fractionatingthe first metathesis product to form an ethylene fraction, a propylenefraction, a butene fraction, and a C₅ fraction; and a second metathesisreaction zone for contacting the propylene with a second metathesiscatalyst, which may be the same or different than the first metathesiscatalyst, to convert at least a portion of the propylene to ethylene and2-butene and form a second metathesis product.
 2. The system of claim 1,further comprising a flow conduit for feeding the first metathesisproduct and the second metathesis product to a common fractionationsystem.
 3. The system of claim 2, further comprising a flow conduit forwithdrawing a propylene product stream.
 4. The system of claim 3,further comprising a control system for adjusting a rate of withdrawingthe propylene product stream to produce a selected ratio of butene topropylene product.
 5. The system of claim 1, further comprising one ormore flow conduits for recycling at least one of the ethylene fractionor the C₅ fraction to at least one of the isomerization reaction zone orthe first metathesis reaction zone.
 6. The system of claim 1, furthercomprising at least one of: a separation zone or a reaction/separationzone for separating isobutene in the butene fraction from normal butenesin the butene fraction via at least one of isomerization andfractionation; a reaction zone comprising a catalyst for the skeletalisomerization of the isobutene to form normal butenes; or a reactionzone for etherifying the isobutene.
 7. A system for the production of C₄olefins, the process comprising: one or more flow conduits for feeding,together or separately, ethylene and a C₅ olefin stream comprising amixture of C₅ olefins including at least one of 1-pentenes,2-methyl-1-butene, or 3-methyl-1-butene to an isomerization/metathesisreactor including a first reaction zone comprising an isomerizationcatalyst and a second reaction zone comprising a first metathesiscatalyst; the isomerization/metathesis reactor for contacting theC₅-olefin stream with the isomerization catalyst in the first reactionzone to form an isomerization product comprising internal-pentenesincluding at least one of 2-pentenes or 2-methyl 2-butene and forcontacting the internal pentenes with ethylene in the presence of themetathesis catalyst in the second reaction zone to form a firstmetathesis product comprising propylene and butenes, including at leastone of 1-butene or isobutene, as well as any unreacted ethylene andunreacted C₅ olefins; a fractionation system for fractionating the firstmetathesis product in the fractionation system to form an ethylenefraction, a propylene fraction, a butene fraction, and a pentenefraction; a metathesis reactor for contacting the propylene with asecond metathesis catalyst, which may be the same or different than thefirst metathesis catalyst, to convert at least a portion of thepropylene to ethylene and 2-butene and recover a second metathesisproduct; a flow conduit for feeding the second metathesis product to thefractionation system.
 8. The system of claim 7, wherein the flow conduitfor feeding the ethylene to the isomerization/metathesis is disposed forfeeding the ethylene to the reactor intermediate the first reaction zoneand the second reaction zone.
 9. The system of claim 7, furthercomprising one or more flow conduits for recycling at least one of theethylene fraction or the pentene fraction to theisomerization/metathesis reactor.
 10. The system of claim 7, furthercomprising a separation zone for fractionating a hydrocarbon streamcomprising mixed C₅ hydrocarbons to form the C5 olefin stream, whereinthe C5 olefin stream comprises less than 0.5 wt % cyclopentene.
 11. Thesystem of claim 10, further comprising a reaction zone for selectivelyhydrogenating dienes in at least one of the hydrocarbon stream or the C5olefin stream.
 12. The system of claim 7, further comprising at leastone of: a separation system for separating isobutene in the butenefraction from normal butenes in the butene fraction via at least one ofisomerization and fractionation; a reaction zone for skeletalisomerizing the isobutene to form normal butenes; a reaction zone foretherifying the isobutene.
 13. The system of claim 7, further comprisinga flow conduit for withdrawing a propylene product stream.
 14. Thesystem of claim 13, further comprising a control system for adjusting arate of withdrawing the propylene product stream to produce a selectedratio of butene to propylene product.
 15. The system of claim 7, whereinthe isomerization/metathesis reactor is a downflow reactor, theisomerization reaction zone comprising one or more beds of isomerizationcatalyst in an upper portion of the reactor and one or more beds ofmetathesis catalyst in a lower portion of the reactor.
 16. A system forthe production of C₄ olefins, the system comprising: anisomerization/metathesis reactor including a first reaction zonecomprising an isomerization catalyst; a second reaction zone comprisinga first metathesis catalyst; an inlet for introducing a C₅-olefin streamcomprising a mixture of C₅ olefins including at least one of 1-pentenes,2-methyl-1-butene, and 3-methyl-1-butene to the isomerization/metathesisreactor for contacting the C₅-olefin stream with the isomerizationcatalyst in the first reaction zone to form an isomerization productcomprising internal-pentenes including at least one of 2-pentenes or2-methyl-2-butene; an inlet for introducing ethylene to theisomerization/metathesis reactor for contacting the ethylene and theinternal pentenes with the metathesis catalyst in the second reactionzone to form a first metathesis product comprising propylene andbutenes, including at least one of 1-butene or isobutene, as well as anyunreacted ethylene and unreacted C₅ olefins; a metathesis reactor forcontacting a propylene fraction with a second metathesis catalyst, whichmay be the same or different than the first metathesis catalyst, toconvert at least a portion of the propylene to ethylene and 2-butene andrecover a second metathesis product; a fractionation system forfractionating the first metathesis product and the second metathesisproduct to form an ethylene fraction, the propylene fraction, a butenefraction, and a pentene fraction.
 17. The system of claim 16, furthercomprising a control system and associated flow conduits to selectivelywithdraw a propylene product stream and control a ratio of buteneproduct to propylene product.
 18. The system of claim 16, furthercomprising a recycle stream for recycling a portion of the pentenefraction to the isomerization/metathesis reactor, and a purge stream forpurging a portion of the pentene fraction.
 19. The system of claim 16,further comprising a catalytic distillation reactor system forconcurrent reaction and separation of a mixed C5 hydrocarbon-containingstream, wherein the catalytic distillation reaction system comprises aselective hydrogenation reaction zone, the catalytic distillationreactor system further configured to recover the C₅-olefin streamcomprising a mixture of C₅ olefins.
 20. The system of claim 16, furthercomprising a catalytic distillation reactor system for concurrentreaction and separation of the butene fraction, wherein the catalyticdistillation reactor system comprises an isomerization reaction zone.